Engineer Design
Resume:
Vijayachandar D C
****************@*****.***
India, Chennai
Professional Snapshot
• Around 6.5 year of total experience out of which 5.5 years of extensive experience in CFD Analysis
• Experienced in CFD Aerodynamics analysis for Passenger car
• Experienced in HVAC, Cabin Panel aiming CFD simulation
• Experienced in front end CFD simulation for commercial and pickup truck
• Experience in CFD Under Hood Thermal analysis for passenger car and truck
• Experienced in CFD analysis for Engine Cooling component like Radiator, CAC, Condenser, EGR cooler
• Experienced in CFD analysis for Automotive exhaust after treatment components like DPF, DOC and SCR
• Experience in creating macros to automate the process
• Coordinating with different design group and giving design suggestion by interpret the result
• Involved in DFSS Projects
Organizational Experience
Chrysler India Automotive (P) Ltd,
Oct’08 Till date, Senior CFD Engineer
April’08 –Oct’08 Modine Thermal System India (P) Ltd CFD Engineer
Altair Engineering India (P) Ltd
Jan’06 – March’08 Project Engineer
Aug’03 – April’04 Lakshmi Industries Production Engineer
Technical Experience Summary Table
Fluent 6.3, STAR CCM+, STAR CD
Analysis Tool
ANSA, Hypermesh, T Grid, Gambit
Meshing Tool
Kuli, HMS
1 D system simulation codes
Catia V5
CAD Tools
Windows, Linux OS and HPC (Linux clusters)
Operating system
Selected Key Projects
For Details please refer to Attachment
Aerodynamic analysis for Electric Car
Full vehicle Aerodynamics Drag (cd) Prediction for passenger car
HVAC Cabin Aiming Study
Active Grill shutter(AGS) optimization and front end CFD simulation for pickup truck
Full vehicle Under Hood thermal analysis for commercial Truck
EGR Cooler Gas side/Coolant side thermal Analysis
CFD Flow Analysis of ATAAC / Liquid cooled CAC
Onshore Assignment
Client: Caterpillar Engineering Design Centre India
Duration: Oct 2006 – March 2008
Involved in various CFD project like Engine After Treatment components of off Road Vehicle, Power train, Stationary
power generator, Marine engine and Hydraulics design of Caterpillar Product.
Roles and Responsibilities:
Downloading the geometry files and extracting CFD domain, meshing and analysis
Post processing the result plotting graphs preparing comparison report for various iteration
Involved in the onshore offshore technical discussions, sending out weekly status reports to the onshore
coordinator
Interact with onshore designers team and suggests suitable design recommendations
Education
ME (Automobile Engineering) first class with distinction from Madras Institute of Technology, Anna University,
India in 2006.
BE (Mechanical Engineering) first class with distinction from University of Madras, Chennai, India in 2003.
Diploma (Mechanical Engineering) first class with distinction from Directorate of technical education, India in
2000.
Personal Details
Address : # 12/2, Chirta Kulam Street, Thiruvanmiyur, Chennai 600 041.
Date of Birth: 13.02.1981
Gender: Male
Language Known: English / Tamil
Marital status: Married
Hobby: Interested in cricket and Reading Books
Passport: G7165365 Valid till January 2017
VISA: Having B1/B2 (USA) Valid till February 2021
Attachment: Details About Key Projects
Key Projects
Projects carried out at Chrysler India Automotive (P) Ltd
Aerodynamic analysis for Electric Car
Scope: Predict and optimize air flow direction around Electric Motor to drive away the heat generated by the motor
Description:
• Air flow pattern near the motor was simulated for the base design then detail study of the flow pattern was
done, Further to direct the flow air duct are attached to draw more air passing through the motor surface. Grill
opening are adjusted to allow optimal quantity of air and the mass flux across the motor was continuously
monitored for each simulation.
Responsibilities Handled:
Importing the Geometry parts, identify and group the components
Cleaning the geometry and generating surface and volume mesh with 20 million cells count
Run Simulation for various design iteration, Post processing the result and preparing comparative reports
I was involved in the onshore offshore technical discussions, sending out weekly status reports to the onshore
coordinator and to ensure timely delivery as per schedule.
Full vehicle Aerodynamics Drag (cd) Prediction for passenger car
Scope: Streamline design and minimize the Drag force around the car to increase the fuel efficiency
Description:
• Aerodynamic drag is one of the main opposing force acting against the car propulsion and by minimizing the
Drag force around the car body we can achieve better mileage. Detail study of flow pattern was done by
analyzing the air flow in various regions such as rear spoiler region, hood region and flow separation near
wake region
• When examining the spoiler region it was identified that flow separation has taken place due to spoiler surface
projected out of sun roof surface, as a remedy redesigning of spoiler profile was done to avoid the separations
• When verifying the car front fascia it was identified that the grill openings was too bigger than the heat
exchanger front fascia, as a remedy grill holes at the top row and holes near fog lamps are removed When
examining the Underhood region it was identified that flow escapes through the gap between condenser and
radiator, as a remedy gap between the heat exchangers are sealed
• In addition to that air induction plates are fixed to guide the air passing through heat exchanger. For the further
reduction of drag air dam and skit plate are attached at the car bottom surface
Responsibilities Handled:
Importing the Geometry parts, identify and group the components
Cleaning the geometry, surface mesh are further refined near small gaps and volume mesh was generated
with 25 million cells count
Run Simulation for various design iteration, Post process and preparing comparative report
Air induction plate,skit plate and air dam surface are modeled to reduce drag
As a Lead, I was involved in the onshore offshore technical discussions, sending out weekly status reports to
the onshore coordinator and to ensure timely delivery as per schedule.
Involved in coordinating with the team member to ensure quality in his part of work.
HVAC Cabin Aiming Study
Scope: Predict and optimize air percentage in HAVC ducts, to monitor flow pattern inside cabin and to calculate average
velocity on aiming points.
Description:
• HVAC and the cabin are modeled with different door opening positions like face mode, floor model
• The duct shapes are optimized to balance the air splitting percentage in each mode
• Cabin was modeled with manikin, flow pattern inside the cabin is simulated and the average velocity on aiming
points was calculated.
Responsibilities Handled:
Importing the Geometry parts, identify and group the components
Cleaning the geometry surface, generating surface and volume mesh with 8 million cells count
Run Simulation for various door mode, Post processing the result and preparing comparative reports
Active Grill shutter (AGS) optimization CFD simulation for pickup truck
Scope: To optimize AGS and study underbody flow simulation with air dam and belly pan
Description: AGS is recent development to prevent Underhood region from extreme cold and it is essential to optimize
the design and study it behavior along with air dam and belly pan to achieve rated air flow across heat exchanger like
condenser, radiator, TOC, etc.,
Responsibilities Handled:
Importing the Geometry parts, identify and group the components
Cleaning the geometry surface, generating surface and volume mesh with 18 million cells count
Run Simulation for various design iteration, Post processing the result and preparing comparative reports
I was involved in the onshore offshore technical discussions with design engineer and testing team, sending
out weekly status reports to the onshore coordinator and to ensure timely delivery as per schedule.
Projects carried out at Modine Thermal System India (P) ltd
Full vehicle Under Hood thermal analysis for commercial Truck
Scope: Predict and optimize air flow pattern and mass flow distribution among heat exchanger (condenser & Radiator)
and to identify the critical area like recirculation (dead zone) near the heat exchanger
Description:
• This analysis was carried out to simulate the air flow pattern and balancing the mass flow rate across heat
exchanger, Positioning of condenser and radiator is most important in balancing the mass flux across the core
region.
• Initially the condenser was placed slightly bellow in front of the radiator top face, simulation results shows that
recirculation at the condenser frame as affected the radiator performance
• In second simulation condenser was attached to the same level of the radiator top frame surface, simulation
results shows uniform air flow across the radiator face and recirculation on the condenser frame was
eliminated
• Finally thermal analysis was carried out to predict the temperature around the heat exchanger surface, radiator
and condenser region are modeled as heat exchanger model with surface temperature
• Pressure drop across each heat exchanger and the mass flux across condenser and radiator face for different
air inlet velocity conditions are simulated
Responsibilities Handled:
Detailed study of Under Hood geometry and grouping the components
Geometry Cleaning up, preparing computational domain
Surface mesh generation and volume mesh is generated with 20 million cell count
Solver for different design iterations, and analyzing the Pressure drop, mass flow split across cooling
component CAC, Radiator and fuel cooler.
Post processing the velocity vector to identify the problematic area like recirculation
Involved in the onshore offshore technical discussions, sending out weekly status reports to the onshore
coordinator and to ensure timely delivery as per schedule.
EGR Cooler Gas side/Coolant side thermal analysis
Scope: To find pressure drop, flow distribution across Gas side/Coolant side and to locate thermal stress
concentration in II iteration
Description:
• EGR cooler consist of gas side circuit and coolant side circuit, hot exhaust gas are passed through gas side
whereas coolant water are pumped through coolant side. Heat liberated from exhaust recirculation gas are
transferred to the coolant water in EGR cooler
• In EGR gas side fins are modeled as porous media and the porous values are computed from pressure
restriction curve. In EGR coolant side either coolant fins coolant baffle are used, surface wrap technique was
used to capture fine details of the coolant fins, Flow distribution across each row of coolant fins are simulated
and the mass flow distribution across each row at various section are calculated
• Local heat transfer coefficient values extracted from the EGR surface are mapped to FEA mesh and FEA
analysis are carried to find thermal stress
Responsibilities Handled:
Geometry Cleaning up, preparing computational domain
Surface mesh generation and volume mesh is generated
Inertia and viscous resistance of the porous media are calculated from pressure restriction curve plotted
against pressure drop verses flow rate.
Pressure drop in the core and mass flow rate through the each core tubes was calculated
Local heat transfer coefficient values are mapped to FEA mesh, for II iteration of thermal analysis.
Post processing pressure and temperature distribution, velocity plot across each section in the core
Involved in the onshore offshore technical discussions, sending out weekly status reports to the onshore
coordinator and to ensure timely delivery as per schedule.
CFD Flow Analysis of ATAAC / Liquid cooled CAC
Scope: To simulate air flow pattern, compute mass flow rate distribution in each core tubes, and to find pressure drop
across ATAAC tanks and heat exchanger core section
Description:
• To increase the volumetric efficiency of the engine, high density compressed atmospheric air is supplied during
the suction stroke and this is achieved by turbocharger during this process temperature of the air is increased
which was cooled by the CAC
• In order to achieve better cooling, CFD analysis was carried to predict and optimize the tank profile to allow
balanced mass flow distribution across porous core tube. ATAAC porous was modeled as porous media
boundary condition and Pressure drop in the inlet and outlet pipe bends was computed in CFD simulation
Projects carried out at Caterpillar EDC India
Under Hood analysis for stationary Engine (Power generator)
Scope: Predict and optimize air flow around Fuel tank, to prevent hot air from the engine striking the fuel tank surface
Description:
• In stationary generator to cool the engine ambient air was sucked through side grills and passed over the
engine, radiator and other heat exchanger and finally it reaches the atmosphere through top opening. Due to
space constraint the fuel tank was kept in front of the engine which is heated by the hot air coming out from the
radiator
• CFD analysis was carried out to simulate air flow around Fuel tank
• In order to prevent the contact of hot air over fuel tank, Additional deflector was attached to divert the flow and
limit the fuel tank surface temperature
Responsibilities Handled:
Detailed study of Under Hood geometry and grouping the components
Geometry Cleaning up, preparing computational domain
Surface mesh generation and Volume mesh generation
Simulating the base design and analyzing the flow path and predict the fuel tank surface temperature
Adding suitable deflector in geometry and optimize the flow pattern and limiting the fuel tank surface wall
temperature
Post processing the velocity vector to identify the problematic area like recirculation
Involved in the onshore offshore technical discussions, sending out weekly status reports to the onshore coordinator
and to ensure timely delivery as per schedule
Analysis of Engine Hood of a Modern Tractor
Scope: Evaluate the pressure force caused by wind force over the hood surface when it kept in open position for
servicing
Description:
• In order to service the engine and other parts, engine hood (engine cover) lifted upright position
• CFD Analysis was carried out to evaluate the amount of pressure force experienced by the hood at various
wind speeds and wind flow directions from 00 to 1800 also the hood opening angle varied from 00 to 90o
• The pressure distribution over the hood was determined to estimate the type of hinge required to hold the hood
even at worst conditions
Responsibilities Handled:
Detailed study of the concept involved.
Geometry Cleaning up, preparing computational domain
Grid generation for different hood position
Solver for different iteration, analyzing the flow simulations, and characteristics involved in the problem, such
as Pressure distribution, over inner and outer surface of the hood.
Post processing the pressure distribution and preparing comparison report for various hood angles, different
speed and angle of attack of wind
Involved in the onshore offshore technical discussions, sending out weekly status reports to the onshore
coordinator and to ensure timely delivery as per schedule
CFD Analysis of Engine after treatment of DPF/SCR
Scope: Pressure drop simulation across DPF/SCR Porous filters
Description:
• In after treatment process in Diesel engine exhaust gas are allowed to pass through the DPF/SCR filters.
Unburned hydro carbons present in the exhaust gas are oxidized with the help of catalyst coated over the
filters, whereas soot particulates present in the exhaust gas are filtered by the core filters
• Pressure drop should be of optimum for efficient engine performance. CFD simulation was carried out to
predict the pressure drop in the filters region. DPF/SCR was modeled as porous media boundary condition.
Responsibilities Handled:
Geometry Cleaning up, preparing computational domain
Generating hybrid grid with hexahedral mesh in the Porous filter and tetrahedral in the remaining parts.
Calculate the inertia and viscous resistance values to feed boundary condition for Porous media
Flow simulation, analysis of pressure and velocity distribution, effects of Porous filter in flow distribution, is
studied.
Post processing the pressure distribution, plotting graphs, calculating velocity uniformity index (V gamma)
values at Porous zone
Involved in the onshore offshore technical discussions, sending out weekly status reports to the onshore
coordinator and to ensure timely delivery as per schedule
Contact this candidate